Supporting brace for footwear inserts

ABSTRACT

The invention relates to orthopedic shoe inserts to support and guide the foot and provides an insert core for shoe inserts with the insert core comprising a support clasp with mutually linked, diagonally extending support arms.

The invention relates to an orthopedic shoe insert to support and guide the foot and provides novel insert cores for shoe inserts, which comprise a support clasp extending essentially longitudinal in reference to the insert core with mutually linked diagonally extending support arms.

Orthopedic shoe inserts are commonly inserted into shoes and here act to compensate or distribute forces in order to support the foot, particularly the arch of the foot, and to guide it in its natural progression of motion. This way the static of the entire body can be improved “from the ground up,” by the insert returning the joints of the foot and consequently also the knee and hip joints into their physiologically correct position or holding them there. Thus, shoe inserts can contribute not only to easing acute foot ailments but they can also be used for the prophylaxis and therapy of complaints and diseases of the knee joint, the hip, the pelvis, as well as the spinal cord. Indications for orthopedic shoe inserts are in particular faulty alignment of the knee and hip, splayfoot, flatfoot, and hollow foot.

In general, shoe inserts are embodied as “long-sole” variants, covering the entire inner sole in a shoe and thus the heel, ball, and toes of the foot. Other variants are shorter, so-called three-fourth inserts, which extend from the heel to the ball of the foot. The positioning of the shoe insert at the foot occurs generally via the heel. Here a recess, material thinning, or a more elastic upholstery element may be provided by which the heel section of the insert is centered at the ball of the heel.

Orthopedic shoe inserts of prior art are designed laminar comprising several material layers. Generally at least one upholstering coating or cover layer is provided at the top facing the foot as well as a mechanically stable, shaping, supportive, and if applicable upholstering layer on the bottom facing the shoe. In order to provide the insert with the supporting and guiding function required for its operation additionally a mechanically solid stiffening element may be provided, which during production is inserted into or between the material layers in a manner known per se and is mechanically connected thereto. The supportive effect of such stiffening elements or “insert cores” is frequently insufficient in orthopedic inserts of prior art, primarily when the insert cannot be individually adjusted to the weight of the patient or the therapy, for example. Additionally, a guiding function is desired which controls the rolling behavior of the foot and allows a physiological line of motion, to the extent possible. Inserts of prior art can fulfill this operational function sometimes only to a very insufficient extent. Additionally, orthopedic inserts of prior art show a large volume in order to achieve the mechanic stability required for their functionality, and then usually need shoes particularly adjusted to the inserts, which leave sufficient space above the footbed. Accordingly the applications for orthopedic shoe inserts of prior art are limited in standard shoes.

The invention is based on the objective to further develop orthopedic shoe inserts in order to overcome the above-mentioned disadvantages. In particular it shall be achieved that in an essentially identical design of the inserts, particularly during production, adjustments to the patient can be implemented easily with regards to the support function and/or guiding function. The provision of a novel construction is also here in the forefront, which allows a simplified production of a series of inserts with differently embodied mechanic support or guidance function in the very same automated production process, simultaneously reducing the setup time.

The technical problem is entirely attained in the provision of a supporting insert core for a shoe insert to support or guide a foot, with the insert core containing a carrier and a support clasp arranged therein, particularly comprising a mechanically stronger material, which can provide the mechanic support function or guiding function of the entire insert. According to the invention the support clasp comprises essentially diagonally extending support arms intersecting, i.e. linked to each other particularly in the area of the arch of the foot, which taper towards the opposite ends of the insert core. At least two rear support arms and at least one frontal support arm or at least two frontal support arms and at least one rear support arm are provided, which form the support clasp of the insert core. According to the invention the support arms each extend diagonally in the insert core and preferably essentially along its longitudinal extension and thus the shoe insert. Here two respective support arms, essentially diagonally opposite each other, form a support bridge as the supporting element of the support clasp. According to the invention a first support bridge is intersected by additional support bridges, also formed by support arms essentially diagonally opposite each other. The support clasp is therefore preferably arranged in the insert core such that it extends in its longitudinal extension essentially along the longitudinal extension of the insert core or preferably the insert itself. This way, the intersected support arms and/or the support arches preferably extend essentially from the heel or the transition of the arch of the foot and the heel to the ball of the toes.

Thus, the invention provides to arrange a support clasp inside the insert core, comprising a carrier essentially made from at least or precisely two intersecting support bridges, which extend mutually linked diagonally in the insert core. Here it is provided that this support clasp essentially performs the mechanical support and guiding function of the insert core and thus the entire shoe insert, with the insert core being a component thereof.

Advantageously this insert can be embodied thinner than shoe inserts of prior art with similar mechanical support and guiding functions. While shoe inserts of prior art achieve the support or guiding function particularly via the great strength of the laminar material of an elastic foam material and thus must be particularly thick at the points of the insert supporting or guiding such that the insert is bulky and would no longer fit into certain narrow shoes, according to the teaching of the present invention a thick, mechanically strong laminar material can be waived for yielding the mechanic support or guiding function.

The embodiment of the mechanic support or guiding function of a support arm of the support clasp is based in a first embodiment of the insert core according to the invention in a higher strength module of the material of the support arm. Alternatively or additionally it may be based on the embodiment with a greater material thickness of the insert core in the area of the support arm. In an alternative or additional variant the embodiment is based on a greater material width in the area of the support arm.

The invention provides that the support clasp in its concrete design and embodiment can be easily adjusted inside the insert core to achieve a certain support or guiding function without thereby the overall structure of the insert core and thus the entire insert changing, particularly with regards to the external dimensions, particularly the thickness of the insert. Advantageously the other structures and materials used in the insert can remain unchanged. The invention therefore allows particularly to use the very same production process for an insert core and/or for a shoe insert in which, with regards to the support or guiding function of the insert, variously embodied insert cores can be easily produced in a fully automated fashion.

The different embodiment of the support or guiding function is achieved according to the invention particularly such that the support clasp comprises several individually embodied support arms, which by changing the material features and/or particularly adjusting/changing the exterior form (thickness, width) their mechanic strength can be individually adjusted. For example, in a second product charge of the insert core or the insert at least one support arm may be embodied with a different material strength and/or particularly a different width than in a first charge. A wider and/or thicker support arm leads, particularly locally, to a higher mechanic strength and thus to a differently embodied support or guiding function of the insert. Inversely, if a beneficially reduced supporting effect and thus a higher mechanic elasticity shall be achieved in a certain zone of the insert it is provided for example primarily to embody the support arm respectively allocated to this zone/section with a lesser material strength, particularly with a lower width.

Inside the carrier the support clasp is embodied from a mechanically stiffer (material) in reference to the other materials of the insert core, here particularly the carrier and also particularly in reference to the other material layers of the shoe insert, which means embodied more resistant and showing a higher elasticity module. For this purpose it is provided in a first embodiment of the invention that the support clasp is embodied from a stiffer material than the other elements of the insert core.

In an alternative or additional embodiment the support clasp represents an integral part of the carrier and is embodied in one piece with the carrier and made from the same material. The support clasp is distinguished from the carrier particularly by a higher material strength. This means, in this case the mechanically stiffer support clasp is achieved by increasing the material strength in the section of the carrier forming the support clasp. If here an individual increase or reduction of the stiffness of one or more support arms shall be achieved, in this embodiment it is provided to increase and/or reduce the material strength locally in the area of said support arm and/or preferably to widen and/or narrow the material zone within a variable zone forming the support arm in the carrier.

In a first embodiment the insert core is therefore embodied comprising several parts, i.e. a carrier and at least one support clasp, which can be produced separately, which preferably comprises a different, particularly mechanically stronger material. In an alternative embodiment the insert core is therefore embodied in one piece and as one part, with particularly the carrier and the support clasp comprising the same material and preferably allowing to be jointly produced in a uniform method.

Advantageously the invention allows a simple adjustment or variation of the mechanic strength of individual or several support arms of the support clasp within an automated production process by a minimal adjustment of the respective tool with a very short setup time. Here a modular structure of the insert core and/or the tool is preferred. For example, the invention allows that within the very same basic tool for the production of the insert core or the support clasp or alternatively the entire insert only individual tool elements need to be exchanged in order to yield support clasps, insert cores, and/or complete shoe inserts with certain mechanic support functions. The automatic production also comprises the automatic exchange of the partial tool elements to determine the mechanic strength of the support clasp according to the specifications of the control program. The invention is not limited to the processing principles described here for the automatic production of insert cores. For example, applicable are here both injection molding processes known per se as well as multilayer lamination processes.

In a preferred embodiment the rigid support clasp represents an injection molded part. Here thermoplastic materials, particularly impact resistant ones are preferred. Preferred are polyethylene, polypropylene, polyurethane, and particularly ethylene vinyl acetate (EVA), as well as mixtures of these components.

Here, individually adjusted insert cores and inserts can be produced in a most economic fashion with regards to the mechanic support function. Simultaneously, by the simple automation of the production process the otherwise manually performed individual production or adjustment methods of distributed components of prior art are avoided with regards to the results yielded and the quality of the product manufactured. The invention allows for the first time the automated industrial production of a plurality of individually confectioned orthopedic shoe inserts in a high, consistent quality while being highly economical. Similar methods are not known from prior art.

In detail it is provided that the insert core according to the invention can be divided into rear sections, which inside the shoe insert are aligned towards the heel, and frontal sections, which are aligned towards the tip of the foot. Further, the insert core can be divided into internal sections aligned towards the inside of the foot and external sections aligned towards the outside of the foot. Overall here a division into four quadrants results, with a rear internal section, a rear external section, a frontal internal section, and a frontal external section. The invention particularly provides that a support arm of the support clasp extending at least in a frontal or in a rear internal section is embodied differently with regards to its mechanic support function than at least one opposite support arm extending in the same frontal and/or rear external section. For example, accordingly the rear support arm extending in the internal section shows different mechanic features than the other rear support arm, which extends in the external section. Additionally, it may be provided for the two frontal support arms that their mechanic stability can be different in the same fashion.

In one embodiment in detail those diagonally opposite frontal and rear support arms, jointly forming a diagonal support bridge, are embodied adjusted to each other with regards to their mechanic stability and support functions and preferably equalized. In variants it is provided here that both are embodied respectively mechanically stronger or alternatively respectively mechanically weaker than the other support arms of the support clasp. Accordingly, in a particular variant it is provided in detail that the frontal support arm extending in the frontal external section is embodied stronger in reference to the frontal support arm extending in the frontal internal section with regards to its mechanic support function. In a preferred additional embodiment the rear support arm extending in the rear external section is embodied weaker with regards to its mechanic support function in reference to a rear support arm extending in the rear internal section. The frontal and rear support arms extending in the diagonally opposite rear internal and frontal external sections form a support bridge, which compared to the other, second support bridge formed by the other support arms extending laterally in reference thereto, crossing the first support bridge, are embodied stronger with regards to the mechanic support function.

The objective of the invention also covers an orthopedic shoe insert comprising the insert core according to the invention as well as a method for its production. The method can be performed automatically: In a first step the insert core may be produced from a carrier and a support clasp, if applicable, produced separately and embodied individually with regards to the mechanic strength. In a second step the individually produced insert core is assembled in a conventional end processing to form a shoe insert.

In a particular embodiment the orthopedic shoe insert is formed from a structured insert core according to the invention, combined with a base sole and if applicable a coating or cover layer facing the foot. In a first embodiment the insert core is inserted into the base layer in a manner known per se and mechanically connected thereto in a fixed manner In a particular embodiment the base layer is formed by a targeted foaming of an insert core according to the invention and comprising the insert core as an integrated form part. Here, it may be provided for example that the insert core according to the invention is completely surrounded in a molding process by a formed mass or is sectionally molded in order to form the orthopedic shoe insert. The invention is not limited to this type of production, though. Alternative methods are the adhesion of the insert core with other components in order to form the shoe insert. Known methods are here a layered adhesion of foam material on the side of the sole core facing away from the foot and facing the foot so that it is integrated in the shoe insert formed in this manner. Additionally, there are other known methods to form shoe inserts. They may be adjusted by one trained in the art knowing the teaching according to the invention such that the insert core according to the invention can be used here in order to form a shoe insert. For example, in a first embodiment of the production method the insert core is inserted into an injection molding tool and subsequently one or more plastic form materials are introduced into the molding tool, particularly injected, namely such that the insert core is either sectionally or entirely surrounded or encased by a form material. The form material will cure in the mold at the insert core to form the orthopedic shoe insert.

Additionally a cover layer may be provided in the shoe insert in order to improve skin tolerance and/or adhesion or gliding features between the core of the insert and the foot to be cushioned or supported. In an appropriate embodiment of the production process for this purpose the insert core is inserted together with the cover layer directly into the molding tool to form the base layer and yielded as a component of the shoe insert. An integral form piece is yielded in a single production process. The form piece yielded in this manner can directly be used as an orthopedic shoe insert without any substantial additional processing steps.

The invention is explained in greater detail based on the attached FIGURE and the description of said FIGURE, without being limited thereto.

The FIGURE shows an embodiment of the insert core 100 according to the invention for the use in an orthopedic insert sole 400. It shows a carrier 200 and a support clasp 300. The lines X and Y respectively indicate the division of the insert core into four sections: the rear internal section 110, the rear external section 112, the frontal internal section 120, and the frontal external section 122. The support clasp 300 comprises mutually linked support arms 310, 320, 312, 322, respectively extending in the above-mentioned sections 110, 120, 112, and 122. The opposite support arms 310 and 312, each extending in the rear sections, are embodied mechanically different according to the invention such that they can perform a differently strong support function. In the embodiment shown this also applies to the two frontal support arms 320 and 322. In the embodiment shown the diagonally opposite support arms 310 and 322, extending in the rear internal section 110 and the frontal external section 122 opposite thereto, form a mechanically particularly strong support bridge, which according to the invention is embodied stronger than the other support arms 312 and 320 extending intersecting it and perform a stronger support function. The invention is not restricted to this concretely shown embodiment.

According to the invention at least one support arm, preferably two diagonally opposite support arms, show a higher mechanical strength which can be individually adjusted. In the FIGURE this is embodied in the support arms 310 and 322. For this purpose they each show a variable zone to implement a material widening 315 and 325 which can be individually adjusted. The material widening is embodied variable in the zone 315, 325, so that by a minimal change in said zone 315, 325 an individual adjustment can be achieved by the means used to produce the support clasp 300.

For a better positioning and shaping of the insert core with the insert the insert core optionally shows a recess 210 in the area of the rear section, which particularly shall be positioned underneath the heel of the foot and centered here. Further, the insert core optionally comprises material reductions 228, 227, which allow flexible sections 220, 222 for the adjustment of the otherwise mechanically stiff insert core to the form of the shoe. The insert core 100 is an integral component of the orthopedic insert sole 400. 

1. An insert core for a shoe insert, comprising a carrier and a support clasp arranged therein with rear support arms and frontal support arms, which intersect in the area of the arch of the foot and taper towards the opposite ends of the insert core with rear sections aligned towards the heel and frontal sections aligned towards the tip of the foot, with sections respectively facing the inside of the foot forming internal sections and sections respectively facing the outside of the foot forming external sections, with support arms extending essentially in diagonally opposite rear internal sections and frontal external sections forming a first support bridge crossing the insert core, which is embodied stronger in reference to the other support arms extending perpendicularly thereto with regards to the mechanic support function.
 2. An insert core according to claim 1, with the embodiment of the strength of the mechanic support function of the support arm being caused by the higher strength module of the material.
 3. An insert core according to claim 1, with the embodiment of the strength of the mechanic support function of the support arm being based in the greater material thickness of the support arm.
 4. An insert core according to claim 2, with the embodiment of the strength of the mechanic support function of the support arm being based on a greater material width of the support arm.
 5. An insert core according to claim 4, with a variable zone being provided in the area of the support arm to adjust the material width.
 6. An insert core according to claim 1, which is embodied in several parts comprising at least one carrier and at least one support clasp.
 7. An insert core according to claim 1, with the carrier and the support clasp being embodied together in one piece.
 8. An orthopedic shoe insert comprising the insert core of claim
 1. 